Technical Specification

TS2 Structural Steelwork Fabrication

and Erection

CBH Engineering Pty Ltd

P | (08) 9236 5350
F | (08) 9236 5370
www.cbh.com.au
TS2 Structural fabrication & erection

Document Control
Document owner: Operations & Engineering Manager

Change Control Policy

Any amendment to this standard must be recorded in the table below.

If substantial changes are made a new version of the document shall be created to preserve
an audit trail.

Review Date Author Description of amendments

A 15/07/2009 T. Tyler Reformatting.
B 20/7/2009 T. Tyler Previously TS 5 & 6
C 30/4/2009 T. Tyler Re-brand
D 13/11/2014 J. McMiles Updates styling and formatting.

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Contents
1. Scope 4

2. Governing Standards 4

3. Material Certification 6

4. Marking of fabricated steel 7

5. Materials identification 7

6. Substitution of material specified 7

7. Compression joints 7

8. Fabribcation 7

9. Shop assembly 11

10. Platforms, walkways, stairways & ladders 11

11. Tolerances 12

12. Encased steelwork 13

13. Inspection 13

14. Painting & protective coatings 13

15. Handling, transporting & storage 14

16. Handling and erection of structural steel 14

17. Grouting 15

18. Site modification of structural steelwork 15

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1. Scope
This specification establishes the principles to be followed in the design, fabrication and site
erection of structural steelwork and the performance requirements of all operations
necessary to complete this work.

This specification is to be read in conjunction with the Scope of Works and General
Provisions as outlined in Exhibit C.

2. Governing Standards
2.1 General
Except where otherwise stated, the works shall be in accordance with the current issue,
including amendments of the relevant Australian Standards. These should include, but not be
limited to those identified herein.

Except as modified by the requirements specified herein or the details on the drawings, work
included in the specification shall conform to the applicable provisions of these publications.

2.2 Standards
AS 1101 Graphical Symbols for General Engineering
AS 1111 ISO Metric Hexagon Commercial Bolts and Screws
AS 1112 ISO Metric Hexagon Nuts, including thin Nuts, slotted Nuts and
Washers
AS 1163 Structural Steel Hollow Sections
AS 1237 Flat metal washers for General Engineering purposes
AS 1252 High Strength Steel Bolts with associated nuts and washers for
Structural Engineering (ISO series)
AS 1393 Coach Screws with ISO Hexagon Heads
AS 1418 SAA Crane Code
AS 1538 SAA Cold-Formed Steel Structures Code
AS 1554 SAA Structural Steel Welding Code
AS/NZS 1554.1 Welding of steel structures
AS/NZS 1554.2 Part 2 Stud welding (steel studs to steel)
AS/NZS 1554.4 Part 4 Welding of high strength quenched and tempered steels
AS/NZS 1554.5 Part 5 Welding of steel structures subject to high levels of fatigue
loading
AS/NZS 1554.6 Welding stainless steels for structural purposes
AS/NZS 1559 Hot dip galvanised steel bolts with associated nuts and washers for
tower construction
AS/NZS 1594 Hot-rolled steel flat products
AS/NZS 3678 Structural steel hot-rolled plates, floor plates and slabs
AS/NZS 3679 Structural steel
AS/NZS 3679 Part 1 Hot-rolled bars and sections
AS/NZS 3679 Part 2 Welded l sections
AS 1650 Galvanised Coating of Ferrous Articles
AS 1657 SAA Code for Fixing Platforms, Walkways, Stairs and Ladders
AS 2338 Preferred Dimensions of Wrought Metal Products Plate
AS 3774 SAA Loads on Bulk Solids Containers
AS 4100 SAA Steel Structures Code
AS B108 Black Cup and Countersunk Bolts, Nuts and Washers.
AS Z5 Glossary of Metal Welding Terms and Definitions

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Reference in this specification of specific clauses of the various codes is intended to highlight
those points and shall not be taken to imply a lesser importance for all other applicable
clauses or codes.

2.3 Document precedence

If conflicting requirements occur in the documents, the order of precedence shall be:

Australian Standards listed in the, Occupational health, Safety and welfare

Regulations Schedule 1, with the amendments specified in this schedule.
The Contract Documents, namely the Scope of Work and Drawings followed by the
Specifications.
Nominated and relevant Australian Standards.
Local, Australian and International codes and standards.

If the Contractor finds any conflicting requirements in the contract the Contractor shall inform
the Engineer before starting the work.

Where a situation arises which is not covered by the documents, the Contractor shall adhere
to internationally accepted design the engineering practices with regard to safety, material
selection, constructability, operability and maintainability and as approved by the Engineer.

2.4 Documentation by contractor

The following documentation shall be forwarded to the Engineer:

Quality Control Manual

Inspection and test Plans
Welding Procedures
Material Certificates
Non-destructive Examination Records
Painting / galvanising Records
Dimensional Inspection Records
As-built Drawings / Sketches
Release Certificates
Bolt Torque Results if appropriate
Shop Drawings

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3. Material certification
All material for fabrication including bolts, nuts and washers shall be clearly stamped /
marked with the manufacturers numbers and cross-referenced to the certified material test
report (CMTR) or certificate or compliance (COC).

CMTRs from the manufacturer shall show the heat / batch number and mechanical and
chemical properties derived from testing of the steel.

Material received without certificates shall be quarantined, pending completion of the above.

3.1 Structural steel

Structural steelwork for use in buildings, open type structures, bins, or otherwise, shall be in
accordance with Australian Standards.

3.2 Mill test certificate

Copies of all Mill Test Certificates covering the chemical and physical properties of the steel
used in the work shall be furnished to the Engineer on request and records shall be kept for
inspection.

3.3 Units of measurement

The steelwork sections and holding down bolt diameters shall be metric units.

3.4 Material supply

All materials shall be of new and unused stock.

All steel shall be free from rust, pitting and other defects. All material shall be thoroughly
straightened in the shop without injury before being worked in any way. Material that has
been split or permanently injured shall not be used.

3.5 Material tests

The Engineer reserves the right to have the Contractor submit for testing, as and when
directed by the Engineer, test specimens of any material or item supplied under this Contract
and used, or intended to be used in the structure.

Any material or item failing to meet the requirements specified for the appropriate test or
failing to comply in any way with the specification may be rejected entirely or, alternatively,
the Engineer may direct that its use be confined to some particular part of the structure.

In the event of the Engineer requiring a test specimen to be cut from a member already
fabricated, and the test proving unsatisfactory, the member may be rejected altogether or
repaired as directed by the Engineer at the Contractor's expense. Should the test prove
satisfactory, all repairs to the member will be carried out at the Principal's expense.

Should any test specimen fail to meet the required specification the entire cost of preparing
the test specimen and carrying out the test shall be borne by the Contractor.

All check analysis and mechanical tests shall be carried out in Australia in a laboratory
approved by the Engineer and registered with the National Association of Testing Authorities,
Australia.

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4. Marking of fabricated steel

All marking of steelwork shall comply with the following requirements and shall be subject to
the agreement of the Engineer.

Each piece of steel work shall be distinctly marked by hand stamping and shall
include orientation marks for ease of erection. Mark number shall not be placed on
the bottom of baseplates or anywhere on the steelwork where they will be hidden
after erection.

The hard stamped mark shall be colour coded by placing a stripe of paint
approximately 25 to 30 mm wide through the mark number. Another similar stripe
shall be placed on the adjacent surface. The type of paint used shall be compatible
with the final coat applied. Marking shall remain clear and legible for a minimum of
12 months when exposed to the weather.

Small loose pieces shall be securely bagged or bundled and clearly marked for
identification. Bolts, nuts and washers shall be in separated containers and each
container shall be clearly marked for, size, type and quantity.

5. Materials identification
The full mark as given on the drawings shall be hardstamped in letters of 15 mm size.

6. Substitution of material specified

Steel conforming to other than the nominated standards may be used, providing that the
design requirements are shown to be satisfied and the Engineers agreement is obtained
prior to the commencement of fabrication.

Steel supplied in accordance with the nominated standards, but having sections and sizes
greater in dimensions and relevant properties superior to those shown on the drawings, may
be used if the Engineers agreement is obtained in each case.

All material shall be new. No second-hand materials shall be incorporated in the works.

7. Compression joints
Connection of members depending on contact bearing (i.e. columns to base plate) shall have
their contact surfaces prepared for direct bearing stress.

8. Fabrication
8.1 General
All fabrication shall be carried out in a workmanlike manner generally in accordance with the
applicable clauses in AS 4100.

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8.2 Cutting and bending

Plates, members, brackets and other steel work shall be cut and bent in compliance with the
following:

Any plates thicker than 16 mm shall not be sheared unless otherwise approved
by the Engineer.

The ends of tubular and hollow sections shall be profiled to fit the shape of the
members to which they connect, and shall not be sheared or flattened unless
otherwise shown on the design drawings or agreed by the Engineer.

Procedures for bending of materials shall be subject to approval by the Engineer.

Normal strength steels up to grade 300MPa may under careful supervision be
bent by limited heating to a temperature not higher than that required to produce
a deep cheery red colour, and allowed to cool slowly. Higher strength steels shall
not be heated without first obtaining the recommendations of the steel
Manufacturer and the prior agreement of the Engineer.

8.3 Punching and drilling of bolt holes

Punched holes shall not be made in material greater than 20 mm thick.

Oversized and slotted holes for high strength bolts will not be permitted unless
shown on the design drawings or otherwise agreed by the Engineer.

8.4 Machined surfaces

Where specified or shown on the design drawings, the contact bearing faces of
adjoining members and plates shall be machined in accordance with Clause
14.4.4 of AS 4100.

Rockers, rollers or hinge gearing sets shall be machined to the radii shown on the
design drawings, with the axis of rotation at right angles to the direction of the
motion of the structural members which they support. Machining tolerances shall
be as shown on the design drawings.

8.5 Camber
Trusses, beams and plate girders having spans greater than 12 mshall be fabricated with
cambers of five (5 mm) millimetres under the self-weight, unless noted otherwise on the
design drawings.

8.6 Splicing in members

All structural members shall be single lengths, except where splices are shown
on the design drawings, or where the Engineer has given prior written approval.

For additional splices, the Contractor must demonstrate the need and provide
calculations for the review of the Engineer prior to fabrication. Splices must be
designed to develop the full splices member strength.

Where shown on the design drawings, column ends with full bearing splices shall
be machined in accordance with Clause 14.4.4.2 of AS 4100.

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8.7 Boxed members

Abutting edges shall be connected and sealed with a continuous weld.

Weld reinforcement ground flush only where shown on the drawings.

Stiffeners and other details that will be enclosed within the box member shall be
subject to inspection by the Engineer before the closure plates are welded into
place.

Where steelwork is required to be galvanized, holes shall be provided in boxed

members to prevent distortion and explosions during the galvanizing process.

8.8 Connections
In general, shop connections shall be welded and field connections shall be bolted, unless
otherwise shown on the drawings. All bolting and welding shall conform to AS 4100 Steel
structures and the specification.

8.9 Bolted connections

All bolts, nuts and washers shall be galvanised. Structural connections shall have
a minimum of two (2) bolts.

Bolting procedure shall be 8.8/TB unless noted otherwise on the drawings. All
high strength bolts shall be installed in accordance with AS 4100.

The Contractor shall supply bolts, nuts and washers of each type, size and length
for both shop and field connections are required for erection and extra amounts
of field bolts, nuts and washers as follows;

a) 5% extra for each bolt type for the first 1000 required. 3% extra for
each bolt type for the remainder required in excess of 1000.

b) Structural bolts that have been fully tensioned (8.8/TB and 8.8/TF)
shall be replaced if they are undone and would need to be
retightened.

8.10 Shop errors

Fabrication errors or potential errors resulting from incorrectly detailed components are to be
reported immediately to the Engineer. The Engineer will consider the action required for
correction or modification of the work.

Should corrections be necessary, written instructions will be given to the Contractors to carry
out such work to the account of the responsible party.

Should fabrication errors be found during erection, the Contractor will be advised and repairs
and/or modifications as considered necessary by the Engineer will be the account of the
Contractor.

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8.11 Inspection during fabrication

During fabrication the Contractor shall permit the Engineer or the nominated representative
free access to the Fabricators Works at all reasonable times for the purpose of carrying out
inspections. Units shall be laid out and fabricated as necessary so that all parts are
accessible for final inspection before transportation to the site.

Where steel has been inspected by the Engineer at the shop, before being delivered to the
site, such inspection shall not relieve the Contractor of the responsibility for the correctness
of the fabricated steel.

8.12 Material
All material shall meet the requirements of AS4100 Structural Steel Clause 2.2.

Steel bolts, nuts and washers shall be to the requirements of Clause 2.3, and the
steel castings to the requirements of Clause 2.4.

Crain rail steel shall be to the requirements of AS1085 and BHP Standards.

8.12 Surface preparation of steel and components

All surfaces to be welded shall be clean and free from paint, oil, debris, scale, oxides and
other foreign material detrimental to welding, for a distance of at least 25 mm from joint
preparation.

8.13 Welding
All welding shall conform to the requirements of AS/NZS1554 as appropriate.

Welding of steel studs to structural steel shall be detailed in AS/NZS1554.2.

All welding shall be general purpose (GP) unless noted otherwise on the
drawings. Where welding is required that does not conform to the above codes,
the necessary procedures and instructions shall be indicated on the Engineers
drawings.

All welds shall be made with the appropriate grade of electrode suitable for the
type of steel being welded. Welds shall be thoroughly chipped to remove slag
and shall be the full size specified and/or as shown on approved drawings.

Unless otherwise shown, all fillet welds shall be continuous welds. Intermittent
welds will not be permitted where members are exposed to weather or corrosive
atmosphere unless the spaces between are continuously seal welded.

Unless otherwise shown, all butt welds shall be complete penetration butt welds
and where possible, shall be double V butt welds except that in the case of butt
welds in plate 40 mm and more in thickness shall be made with low hydrogen
electrodes. Over reinforcement of butt welds and pronounced bumps shall be
ground off. Subject to the Engineers approval. Beams, flange plates, web plates
and cord members of long trusses may be butt welded in the shop to form any
long lengths required provided that such splices do not come within the middle
third of the member, in the case of compound members, the splices in the
individual units shall be staggered by not less than 600 mm. all butt welds in

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tubular and boxed members shall be backed by suitable mild steel backing rings
or plates.

To enable complete assemblies to be erected, site welding of individual members

attached to main shop fabricated pieces shall be permitted as indicated on the
Engineers and fabrication drawings. The individual members shall be welded to
their main components at ground level.

Adequate mobile welding facilities shall be provided for this operation.

When the occasion arises due to discrepancy, inaccuracy or other reasons, site
welding may be used. All relevant details and procedures must be approved by
the Engineer before site welding can commence.

Fabrication drawings of welded connections shall specify as a minimum:

a) Relevant design standards

b) Specification grade of parent weld/electrode material
c) Location, type, size of weld and effective lengths
d) Weld category GP or SP
e) Details of non-standard welds
f) NDT (non destructive testing) requirements

Qualification of welding procedures and personnel shall be carried out as detailed

in AS/NZS 1554.

Weld procedures shall be approved and personnel shall be qualified prior to

commencing welding on structural steel or components.

Documentary evidence of personnel qualifications shall be submitted to the

Engineer for review prior to fabrication.

9. Shop assembly
Sections of the fabricated steelwork shall be shop assembled when specified on the
drawings. During shop assembly, drifting of misaligned holes shall not be permitted.
Misaligned holes shall be drilled and reamed to a larger size and larger bolts fitted, subject to
the agreement of the Engineer.

10. Platforms, walkways, stairways & ladders

The platforms, stairways and ladders and associated attachments shall conform to:

AS 1657 Fixed platforms, walkways and ladders design, construction and

installation and the following requirements.

10.1 General
All decking shall be firmly fixed to the supporting steelwork.

Shop fixings shall be welded and field connections shall be bolted unless otherwise shown
on the drawings.

Bolts or other fixings on the surfaces of platforms, landings and walkways shall be
countersunk flush with the surfaces.

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10.2 Guard rails

The dimensions of components used for guard railing shall be as shown on the drawings or
on the recommendations of AS 1657 when not shown on the drawings.

The top rail of all railing shall present no obstruction that may break or prevent a handhold.

All welds shall be continuous and ground smooth.

10.3 Floor grating

Floor gratings shall be as specified on the approved drawings.

Gratings shall be furnished to be continuous over two spans, or more where practicable.
Grating panels shall be banded. Longitudinal and cross bars in adjacent sections shall be in
line when erected end to end.

Where removable grating is required, the maximum grating panel shall be normally 1500 mm
x 1200 mm wide.

10.4 Raised angular pattern floor plates

Floorplates shall be skid resistant BHP raised pattern (or equal) Grade 250 steel plates to AS
3678, not less than 6 mm thick welded or bolted to the supporting steel as noted on the
design drawings. Floorplate shall be fabricated with lengths to be continuous over two spans
or more with practical, smooth cut to the dimensions indicated on the design drawings.

When removable froorplate is required, holes in the supporting steel shall be drilled in the
field after erection, using the shop drilled, countersunk holes in the floorplate as a template to
ensure a proper fit. A minimum of four (4) bolts per piece shall be provided. Two (2) lifting
holes shall also be provided in each removable floorplate.

11. Tolerances
Tolerances for shop fabricated steel and field erected steel shall comply with the relevant
requirements of AS 4100, unless specified otherwise on the design drawings or as specified
below.

The deviation in plan position of a column shall not exceed 5 mm from its specified position
at any point. The base of a column shall be within 5 mm of its correct level and the top of the
column shall be within 3 mm of its correct level.

The deviation in level of a beam or a girder shall not exceed 5 mm from its specified level.

Tolerances for overhead crane rails shall comply with the relevant requirements of AS
1418.1, Section 7 in addition to the following:

The centre to the centre distance between the two crane rails shall not deviate
from the spacing specified on the drawings by more than 3 mm.

The plan position of each crane rail shall not deviate by more than 3 mm from the
specified position shown on the drawings.

The level of the top of the rail in an unloaded condition shall not deviate from the
elevation shown on the drawing s by more than 3 mm.

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The horizontal alignment of each rail end at joints shall not deviate by more than
2 mm. the top face of each rail end at joints shall be flush.

12. Encased steelwork

Steelwork shall be encased in concrete as detailed on the approval drawings and shall
comply with the following requirements:

Steelwork shall not be encased or built in until all connections and surface
preparations have been reviewed and approved by the Engineer.

Welding of reinforcing steel / anchors shall be carried out as detailed in AS/NZS

1554, Part 3, Welding of Reinforcing Steel.

Concrete shall be Grade 32 MPa with a maximum aggregate size of 10 mm,

unless specified otherwise on the drawing.

13. Inspection
Welding of shop fabricated structural steel and field welding shall be subjected to Non
Destructive Tests (NDT) as follows:

Visual inspection of 100% of all welds shall be performed.

Fillet welds, 5% by Magnetic Particle Inspection (MPI).

Full and partial penetration butt welds, 10% by radiography.

Levels of inspection shall be increased in the event that the defects exceed the
level as given in Tables 6.2.1 and 6.2.2 of AS/NZS 1554.1.

14. Painting & protective coatings

Corrosion protection of steel and components shall be carried out as described in Standard
Specification TS 4 - Painting and Protective Coatings or as nominated on the drawings.

During site handling, storage and erection the Contractor shall take all necessary precautions
to prevent damage to the protected steelwork surfaces.

All painted and protective coating to the steelwork damaged by the Contractor during
erection shall be cleared, prepared and restored in accordance with the standard
specification above.

The Engineer reserves the right to inspect all fabricated structural steel (shop and field) prior
to application of protective coatings

The Contractor shall give the Engineer three (3) working days written notice of intension to
proceed with the application of the coatings to any steelwork.

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15. Handling, transporting & storage

Handling of structural steelwork by the Contractor during all phases of fabrication and
erection shall comply with the following requirements:

Steelwork shall be handled and stored by methods and equipment that will not
result in overstress, deformation or damage to protective coatings. Members shall
not be stored directly in contact with the ground.

Members bent or buckled by the Contractor during handling shall be liable to

rejection. Any steelwork that is deformed as a result of handling, storing and
transporting and which prevents the proper assembling and fitting up of parts
shall be replaced or corrected by the Contractor. The method of correction shall
be subject to the agreement of the Engineer. Damage to paintwork during
handling and erection shall be repaired in accordance with Standard Specification
TS 4.

Bolts, nuts and washers shall be stored in grit free containers, in weatherproof
premises. Loose pieces for connections shall be attached to their respective
members and clearly marked for identification.

During site handling, storage and erection, the Contractor shall take all necessary
precautions to prevent damage to painted or other protected steelwork surfaces.

All protected steelwork damaged by the Contractor during handling and erection
shall be cleaned, prepared and restored in accordance with Standard
Specification TS 2.

16. Handling and erection of structural steel

Handling and erection of steelwork shall comply with Section 15 of AS 4100 and the following
requirements.

The Contractor shall submit to the Engineer for agreement, details of the
equipment and methods proposed for use in the erection of the steelwork. All
erection gear and equipment shall be of adequate strength and comply with all
applicable Statutory Acts and Regulations. The agreement of the Engineer shall
not relieve the Contractor of responsibility for the adequacy and safety of the
work during erection.

During erection, the work shall at all times be securely bolted, guyed or braced.
The Contractor shall ensure the stability of the structure at all stages or erection
and shall supply the necessary temporary bracing. At the request of the Engineer
the Contractor shall submit certified engineering computations for stability of the
structure.

Prior to erection of steelwork, concrete surfaces shall be prepared and levelling

plates or shims set in place. All shims and plates shall be galvanised.

All erection bolts used in welded construction may be tightened securely and left
in place or removed and the holes filled with weld metal and ground flush.
Permanent welding shall not be undertaken until correct alignment, plumbing and
levelling has been completed and approved by the Engineer.

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Drift punching to match misaligned holes will not be permitted. Misaligned holes
shall be drilled and reamed to a larger size and large bolts fitted or corrected by
other means to the agreement of the Engineer.

All bolting carried out by the Contractor shall comply with the following
requirements:

a. Bolts shall be assembled with washers under the part to be turned and
shall conform to the requirements of AS 4100.

b. High strength bolts shall be tightened in accordance with AS 4100.

c. Load indicating and other types of bolts designed for special tightening
procedures shall only be installed where shown on the drawings or with
the agreement of the Engineer.

17. Grouting
17.1 General
Grouting for base plates shall be of two (2) types, flowable non-shrink and dry pack mortar
and shall be indicated on the design drawing.

17.2 Flowable non-shrink grout

Epirez 5137 Epoxy grout or equivalent approved flowable non-shrink grout shall be mixed
and placed in accordance with the manufacturers instructions in the locations shown on the
drawings.

17.3 Non-shrink grout (structural)

The acceptable grout shall be an approved proprietary brand. Grout shall as dry as
practicable for the purpose.

The grout shall be rammed under the full area of the baseplate, either by ramming from the
opposite sides simultaneously or ramming against a fixed form. The edges of the grout shall
be neatly tapered at 45 from the baseplate edge to the concrete foundation.

18. Site modification of structural steelwork

18.1 General
No modification that is liable to effect the strength of a structural member, the efficiency of a
joint, or the integrity of a structure shall be made without the prior approval of the Engineer.
Such field fabrication and sub-assembly as may be necessary shall conform with the
requirements of the specifications.

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18.2 Modifications and corrections

Procedures and method shall be submitted to and approved by the Engineer.

18.2.1 Cutting

Site cutting shall be wherever possible by a mechanical process. Where flame

cutting is necessary, an allowance shall be left for grinding of ragged edges to
ensure a smooth finish.

18.2.2 Holding

Holes for bolts shall be drilled. Burning of such holes will not be permitted.
Correction of misaligned holes may be achieved by reaming or, subject to the
approval of the Engineer, by filling badly misaligned holes with weld metal, grinding
flush and redrilling correctly.

18.2.3 Repositioning

Where welded fitments need positioning, the existing weld shall be removed, where
possible, by chipping, grinding or gouging. Where the fitment has been removed, the
affected area shall be ground smooth. Fitments shall be removed using the same
attachment as specified on the approved detail drawings.

18.2.4 Finishing

Wherever remedial work has been carried out, the affected area shall be cleaned,
burrs, slag and weld spatter removed and the paintwork made good in accordance
with Standard Specification TS 4.

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